5S Store May 2019

MAY 2019

www.the5sstore.com 978-842-4610

PUTTING A STOP TO THE WORKAROUND FIX IT OR TOSS IT Do you have a tool that keeps malfunctioning, but you’ve never properly got it fixed? You get annoyed every time you go to use it, then you find a temporary solution, a workaround, and get by. You continue on until that workaround gives out, and then the cycle repeats itself. Just this morning, I attempted to use a utility knife to open some packaging. Now, every time I go to use this thing, it’s jammed. Each time, I get annoyed, fiddle with it, and try to use a pencil or other tool to unlock the safety mechanism and release it. Eventually I toss it aside and find something else to open the package. It’s a ridiculous cycle — and it’s even more absurd that I don’t have a Phillips screwdriver at the office to fix the knife. I’m pretty sure one of our employees who handles our shipping encounters the same problem. Since we don’t have a system in place, he falls into the same trap I do: finding a workaround instead of a solution. Do you have a process in place for reporting issues in your warehouse? Do your employees? Or do they just deal with the problem and find a temporary solution that gets the job done even if it’s not the most efficient method? While part of the issue here is not having the right tools, the bigger problem is not having the right system in place. As soon as we know there’s an issue with the knife, we should have

a system in place to fix it. If it can be repaired, that’s great. We’ll fix it and continue to use it. If not, we’ll toss it and go to our designated cabinet, marked to indicate there are more knives inside, and get a new one. We’ll also fill out a form to indicate that we’ve taken one from the cabinet. This form includes the SKU number, so the buyer can easily order more when it comes time. 5S is all about continuous improvement. If something isn’t working, someone needs to speak up. 5S goes beyond just steps and cues; there needs to be a culture where employees feel empowered to point out problems. When people are not comfortable, they tend to find a way to work with the challenges instead of finding a solution. I’m as guilty as anyone, as that utility knife goes to show you. I sit there stalling a lot of higher priority tasks while trying to rebuild the knife. Minor calls like that don’t require my involvement, but we do need SOP in place to make those efficient improvements.

So, you know what I’m doing right now? I’m tossing out the knife. Then I’m going to make sure we have extra knives stocked and put a visual aid of the equipment on the outside of the closet where they’re stored. That way, my shipper knows exactly where to find them. It’s in line with 5S best practices. We should have a replacement for anything in the stock room in case it breaks, labels to know where they go, and the SKU numbers available so we can easily order more. Inside this newsletter, you can read more about a tool that will improve equipment effectiveness at your facility. I’m excited to see what you think. Then you’ll hear from a total productive maintenance (TPM) expert on why you need to make sure your warehouse is shining for inspections.

Until next month,

David Visco

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NO PLANE, NO GAIN

4 BENEFITS OF TRAVELING FOR BUSINESS

EXPANDING YOUR NETWORK Once you know everyone at your workplace, meeting new people becomes less likely. Business trips, and travel in general, are great ways to make new connections. A survey done by Virgin Atlantic in 2015 estimated that 1 in 5 people have done business with someone they met on a plane. There’s potential to build social relationships too. Don’t be afraid to strike up a conversation with someone new! predisposes your mind to think differently than it normally does. Therefore, business trips are beneficial for brainstorming new strategies. You can’t just rely on what you know; you have to innovate and experiment. Once you’re back in the office, your newfound creativity will help you tackle challenges more effectively. IMPROVING YOUR CREATIVITY Being in a new environment naturally

We don’t normally think of business trips as the most relaxing way to spend our time. Unlike vacations, the schedules are rigid, the mornings are early, and the conference rooms never seem to be a comfortable temperature. However, here are four benefits to going on business trips, both for your employer and yourself. ENHANCING YOUR ADAPTABILITY International business trips can be especially nerve-wracking. You might have to interact with people who speak a different language, figure out how to get to your hotel or conference center by yourself, or try a new restaurant out of your comfort zone. (Not every city has a Starbucks — at least, not yet.) While these may seem like negatives, they are actually opportunities to become more adaptable in everyday life. If you can roll with the punches in a new environment, you’ll be able to do it so much better during the daily grind.

a lot of business travel, sign up for a frequent flyer program and get points on your company’s dime. Put them toward that vacation you’ve been saving for without spending any of your own money. Of course, if your business trip leaves any room for R&R, take advantage of it. You might be there for work, but you’re in a new city with tons of opportunities to learn and explore. Just because you’re there on business doesn’t mean fun is out of the question.

RACKING UP THOSE FREQUENT FLYER MILES This benefit is more for you than for your

job. If you anticipate

HOW TPM KEEPS EQUIPMENT RUNNING

If there’s one mindset change John Kravontka, continuous-improvement consultant and president of TPM Unlimited LLC, wants to encourage, it’s getting out of breakdown mode. With 45 years of experience, John knows the value of maintaining machinery and the role lean management plays.

John recalls one of many scenarios that demonstrates the effectiveness of TPM. A piece of equipment had auto lubrication with a visible reservoir to see if the lubricant was low. The reservoir hadn’t moved for a week. During their daily PM check, the operator noticed and reported it. “The week before, there had been an electrical storm that caused a power outage,” John says. “We rebooted the equipment, but the loop wasn’t pumping anymore. It turned out this was a common problem, and we caught it in other places. It was huge.” With TPM, teams identify what needs to be checked daily. Operators have input into the solution, and everything is labeled with visual cues and instructions. Inspections are

John’s lean management journey started

reversal of the way you typically think about equipment. The standard is to come to equipment when it’s broken down and figure out what went wrong. TPM looks at it from a different direction: It’s running, so what do I have to do to keep it running?” It’s clear to John that TPM provides a better way to recognize when something isn’t working. “TPM is a way of standardizing. It became part of our daily operation and made our process much more visual.” John adds, “That’s where 5S comes in with visuals, so you can tell immediately. If the needle is outside of the green, you’ve got a problem.”

at the beginning of his career, when he was an apprentice at an aerospace company. As a maintenance tech, John says he “learned a lot, made mistakes, and got paired with experienced mechanics.” The company began to implement TPM, and when John was offered the opportunity to learn more, he jumped at it. John quickly recognized that TPM’s principles aligned with his work as a maintenance tech.

“I got excited about what it could do for equipment,” John says. “It’s a 180-degree

standardized, and equipment is maintained. In short, everyone benefits.

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LILLY’S WAREHOUSE

WHY THIS VISUAL TOOL FLIES OFF OUR SHELVES THE STRAIGHT-TALKING POWER OF GAUGE LABELS

A LOVE LETTER TO SPRING

Sigh. I remember the good old days: David and I sitting in our favorite spot in the cushy chair, relaxing at the end of a busy day at the warehouse. Now there’s someone new there, and he’s taking up a lot of space — in more ways than one. I didn’t know it when he arrived, but it seems that Kingston is here to stay.

Okay, I’ll stop barking nostalgic and start woofing about something I’m happy about — spring! I love this time of year, don’t you? I can run around outside without freezing my fur off! It means fuzzy squirrel tails to chase again. The world comes alive with so many wonderful scents to smell. It’s beautiful!

Sigh. I love you, spring.

SHRIMP SAUSAGE SKEWERS

Lean management relies on visual tools to communicate information to teams. These tools are developed to take the guesswork out of inspections. At a glance, an employee can determine if something is functioning or not. They enable teams to keep equipment — and consequently, production — operating with fewer breakdowns and halts in the manufacturing process. If I ever need a reminder of this, I need only look at the tool we sell every day: gauge marking labels. These color-coded visual tools are so simple yet so effective for communicating the health of equipment. Gauge labels make it easier for teams to inspect and maintain equipment. Anyone walking by can easily tell if levels are acceptable or in the danger zone. Using a simple green, yellow, and red color scheme, the labels can be placed over any type of gauge to indicate, at a glance, acceptable or dangerous levels of pressure from that equipment. If the gauge labels indicate the equipment is in the red zone, a team member can leave a problem tag to indicate the equipment needs to be checked. Unhealthy gauge levels are communicated to engineers, and the problem gets solved. With the right processes in place, gauge marking labels are an important part of a healthy 5S facility. Standardizing labeling is a key component of any TPM program, and presized gauge labels that fit your equipment can be used throughout your plant to identify acceptable or dangerous operating ranges. With everyone trained on the process, teams can assess the functionality of equipment during the normal course of a day with a drive-by inspection. Gauge marking labels take no time to install, are simple to use, and are crucial to the productivity of machinery. These benefits at a low price make them one of our most popular visual aids.

INGREDIENTS

DIRECTIONS 1. Heat your grill to medium-high. 2. In a bowl, combine all ingredients for creole seasoning. 3. In a large bowl, combine the shrimp, zucchini pieces, and sausage pieces, and cover them with the olive oil. 4. Add creole seasoning and mix well until all ingredients are covered. 5. Load up skewers with alternating pieces of shrimp,

1/2 pound raw shrimp, peeled and deveined 1/2 pound cooked sausage, cut into 1-inch pieces 2 zucchini, cut into 1/2-inch cubes 2 tablespoon extra-virgin olive oil Wooden skewers, soaked in water for 30 minutes

Creole Seasoning Ingredients •

2 tablespoon paprika

1/2 tablespoon garlic powder 1/2 tablespoon onion powder

sausage, and zucchini until they’re full.

6. Grill skewers until shrimp are well-

1/2 tablespoon cayenne or chili powder

cooked (6–8 minutes).

1/4 tablespoon dried oregano 1/4 tablespoon dried thyme

Order your gauge marking labels here at the5sstore.com/circle-gauge- marking-label.html.

Inspired by PaleoLeap.com

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PRST STD US POSTAGE PAID BOISE, ID PERMIT 411

978-842-4610 www.the5sstore.com

16 Lomar Park, Unit 8 Pepperell, MA 01463

INSIDE THIS ISSUE

1 | Find a Better Solution

2 | 4 Benefits of Traveling for Business A TPM Expert 3 | Our No. 1 Fastest-Selling Tool Lilly’s Warehouse Shrimp Sausage Skewers

4 | A Healthy Snack

SNACKING

or maintain weight all benefit from healthy snacking throughout the day.

People who have high cholesterol or diabetes can better maintain their cholesterol and blood glucose levels if they eat frequently during the day. For athletes, snacking helps distribute the consumption of nutrients their body needs throughout the day instead of all at once. This way, their energy levels stay the same instead of fluctuating with their meal times. If you find yourself in need of a quick bite, think clementines and almonds instead of chips and Pop-Tarts. You’ll still satisfy your hunger without jeopardizing your health or increasing your waistline.

WHAT IS IT GOOD FOR?

There are many different opinions on the healthiness of snacking. Some people think of snacks as processed foods with high calories, but snacks don’t have to be junk food. Depending on what snacks you’re eating, and how often, these little in- between-meal bites can be highly beneficial or detrimental to your overall health.

HEALTHY VS. UNHEALTHY SNACKS People snack when they’re hungry, but they also do it when they’re stressed, bored, or have a habit. When people snack on unhealthy junk food when they’re bored, the result is weight gain. An excellent way to avoid unhealthy snacks is to surround yourself with healthy alternatives. Fill your fridge and pantry with whole grains, fruits and vegetables, and nuts and legumes. With those in your kitchen, you’ll have plenty of healthy options to choose from when you’re hungry. WHO BENEFITS FROM SNACKING? Depending on your weight, fitness level, and medical conditions, snacking throughout

the day can be more effective than eating three large meals a day. Individuals who are crunched for time, have particular health conditions, are athletic, or are trying to lose

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